S 标准培训教材

6

Overview

SixSigma:-ADefinition-AppliedtoGE-GEQualityInitiative-WhyThisApproach?-OriginofSixSigma-The“BreakthroughStrategy”-ArrivingatSigmaSixSigmaStructureKeyConcepts&ToolsAPracticalExampleAnOverviewNotalotofDetails!!6

Overview

“SixSigma”

Ifwecan’texpresswhatweknowintheformofnumbers,wereallydon’tknowmuchaboutit.Ifwedon’tknowmuchaboutit,wecan’tcontrolit.Ifwecan’tcontrolit,weareatthemercyofchance.MikelJ.HarryPresident&CEOSixSigmaAcademy,Inc.ARigorousMethodforMeasuring&ControllingOurQuality“...willbringGEtoawholenewlevelofqualityinafractionofthe

timeitwouldhavetakentoclimbthelearningcurveonourown.”JohnF.Welch,Jr.1995GEAnnualReport6

Overview

WhatDoes“Sigma”Mean?

SigmaisaMeasureoftheConsistencyofaProcessIt(isAlsothe18thLetterintheGreekAlphabet!WhyDoesGENeedAQualityInitiative?GERaisingTheBarNewGoaltobe“BestintheWorld”vs.#1or#2CustomersareExpectingMore,weMustDeliver“Ship-and-fix”ApproachnoLongerToleratedintheMarketAimtoSpeedPastTraditionalCompetitorsin5YearsGoalConsistentwithReducedTotalCostsWeMustAcknowledgeOurVulnerabilitiesPoorQualityThatImpactsCustomersProblemswithNPITooHighInternalCosts6

Overview

WeNeedaMajorInitiativetoMoveFromWhereweAretoWhereweWanttobe6

Overview

WhyDoesGENeedAQualityInitiative?40%35%30%25%20%10%15%5%CostofFailure(%ofSales)DefectsperMillion3.4233621066,807308,537500,000Sigma654321

EstimatedCostofFailureinUSIndustryis15%ofSales;TakingGEFroma3toa6CompanyWillSave~$10.5BillionperYear!Why“SixSigma”?ProvenSuccessfulin“Quality-Demanding”Industriese.g.,Motorola,TexasInstruments(manyprocessstepsinseries)ProvenMethodtoReduceCostsHighlyQuantitativeMethod–ScienceandLogicInsteadofGutFeelIncludesManufacturing&Service(closetocustomer)andProvidesBridgetoDesignforQualityConceptsHasSupportandCommitmentofTopManagementItWorks!!!6

Overview

Sigma3456SpellingMoneyTime1.5

MisspelledWordsperPageinaBook1

MisspelledWordper30PagesinaBook1

MisspelledWordinasetofEncyclopedias1

MisspelledWordinalloftheBooksinaSmallLibrary$2.7MillionIndebtednessper$1BillioninAssets$570

Indebtednessper$1BillioninAssets$63,000

Indebtednessper$1BillioninAssets$2

Indebtednessper$1BillioninAssets31/2MonthsperCentury21/2DaysperCentury30MinutesperCentury6SecondsperCentury6

isSeveralOrdersofMagnitudeBetterThan3!!!Sigma:AMeasureofQuality6

Overview

WhereDoes“SixSigma”ComeFrom?

MikelJ.HarryoneoftheOriginalArchitectsPreviouslyHeadedQualityFunctionatABBandMotorola

NowPresident/CEOofSixSigmaAcademyinPhoenix,ArizonaHasConsultedforTexasInstruments,AlliedSignal(andothers)CurrentlyRetainedbyGEtoTeachtheImplementation,DeploymentandApplicationofSixSigmaConcepts&Tools

LearningfromThoseWhoHavehadSuccessWith6WillAccelerateitsImplementationatGE6

Overview

So...WhatisSixSigma?

AMeasurementSystem

AProblem-SolvingApproach

ADisciplinedChangeProcess“THESIXSIGMABREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl6

Overview

How

DoWeArriveatSigma?Measuring&EliminatingDefectsisthe“Core”ofSixSigmaMeasurementSystemIdentifytheCTQsLookforDefectsinProductsorServices

“CriticaltoQuality”CharacteristicsortheCustomerRequirementsforaProductorService

CountDefectsorfailurestomeetCTQ

requirementsinallprocessstepsDefineDefectOpportunities

AnystepintheprocesswhereaDefectcouldoccurinaCTQ

ArriveatDPMO

UsetheSIGMATABLEConvertDPMOtoSigma

DefectsPerMillionOpportunities23456308,53766,8076,2102333.4PPM

DefectsperMillionofOpportunity

SigmaLevel6

Overview

MeasurementSystem23456308,53766,8076,2102333.4PPM

SIGMALEVEL

DEFECTSperMILLIONOPPORTUNITYIRSTaxAdviceBestCompaniesAirlineSafetyAverageCompanyGEAirlineBaggageDoctor’sPrescriptionRestaurantBills

AverageCompanyin3to4RangeSomeSigma“Benchmarks”6

Overview

MeasurementSystemAGraphic/QuantitativePerspectiveonVariationAverageValueManyDataSetsHaveaNormalorBellShapeNumberofPeopleArrivingatCRDTime7:007:157:307:458:008:158:308:459:009:156

Overview

ProblemSolvingApproachCenterProcessReduceSpreadXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXOff-TargetUnpredictableOn-Target

6HelpsusIdentifyandReduceVARIATIONdueto:-InsufficientProcessCapability-UnstableParts&Materials-InadequateDesignMarginTargetUSLLSLTargetUSLLSLTargetUSLLSLCenterProcessReduceSpreadOff-TargetUnpredictableOn-TargetDefects6

Overview

ProblemSolvingApproach“LowerSpecificationLimit”“UpperSpecificationLimit”LessVariationMeansFewerDefects&HigherProcessYields

6

Overview

ProblemSolvingApproachKeyComponentsof“BREAKTHROUGHSTRATEGY”MeasureAnalyzeImproveControl

IdentifyCTQ&CTP(CriticaltoProcess)VariablesDoProcessMappingDevelopandValidateMeasurementSystems

BenchmarkandBaselineProcessesCalculateYieldandSigmaTargetOpportunitiesandEstablish

ImprovementGoalsUseofParetoChart&FishboneDiagrams

UseDesignofExperimentsIsolatethe“VitalFew”fromthe“TrivialMany”SourcesofVariationTestforImprovementinCenteringUseofBrainstorming

andActionWorkouts

SetupControlMechanismsMonitorProcessVariationMaintain“InControl”ProcessesUseofControlChartsand

ProceduresAMixofConceptsandToolsWillAlsoIntegratewithNPIProcess6

Overview

DisciplinedChangeProcessANewSetofQUALITYMEASURES

CustomerSatisfactionCostofPoorQualitySupplierQualityInternalPerformanceDesignforManufacturability

WillApplytoManufacturing&Non-ManufacturingProcessesandbeTracked&ReportedbyEachBusiness6

Overview

StructureQualityCouncil

Members:Labs&Functions“Pipeline”&BBProjectPrioritiesTraining&CertificationMeasurements&RewardsCommunicationsChampions

Leadership:OverallInitiativeProjectFundingHR:Training&RewardsBlackBelts

Lead6ProjectTeams“Measure/Analyze”“Improve/Control”OutwithBusinessesHereatCRDMasterBlackBelts

Teach6

MentorBlackBeltsMonitorBBProjectsWork“Pipeline”ProjectsAResourcePoolTeamMembers

Learn/Use6ToolsWorkonBBProjectsPartofTheJobOutwithBusinesses6

ProjectswiththeGEBusinesses

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Loss1

Loss3Rejects

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Yield

YieldNumberofOperationsNumberofOperations1.001.000.900.900.800.800.700.700.600.600.500.500.400.400.300.3000.100.000.001101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000ProcessMeanCenteredonEachOperationProcessMeanCenteredonEachOperation1101001,00010,000100.0001,000,0001101001,00010,000100.0001,000,000RolledRolled

Yield

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EntitlementAchievablePerformanceGiventheInvestmentsAlreadyMade

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ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

TheGoalTheVariables

TimeofDeparturefromHome&RouteTakentoWorkTheApproach

Try3PotentialRoutesatCurrentDepartureTime(7:45),SelecttheBest&VarytheDepartureTime‘tilwegetto15MinutesTim涂eo副fD史epa模rtu理re3217:1迷57:307:4莫58:0捏08:15Rou壤teComb避inat层ionSele堪ctedThe袜Resu挥ltUse太Rout秒e2五andLea偶ve乔at漆7:1缴5t贫oR哄eac造hG串oal6Ove脖rvi砌ewUsi假ng痕“De贯sig韵no可fE决xpe辈rim撇ent迟s”据(DO讯E)Time似of碑Depa牵rtur耳eDOE偏(i)窑Bett筋erA灰ccou接nts激for冷Inte魄ract励ive鼠Vari违able凯sMi蠢ssed困by逝“One劣Fac梢tor中ata嚼Tim敬e”,弓and蜘(ii)拼Eff色icie巴ntly宣Sea何rche谁sfo壮r“S厦weet贱Spo伏t”i指nPa弊rame证ter克Spac蓄eThe能Va诵ria谷ble盒sTim张eo误fD痰epa悔rtu录re贩fro库mHom栗e&肢Ro耗ute垒Ta汇kento论Wor使kTheApproach

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ReduceCommutetoWorkto15Minutes(withoutworkinganabnormalworkschedule)

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FLOURUsi奏ng仙a1栋2S妙tep察Pr俩oce厌ss6Ove津rvi押ewThe“BETTERBREAD”CompanyStep1Selecting“CriticaltoQuality”(CTQsorY)Wha变ti熊sI养mpo棋rta雁nt壳to构the拼Cu只sto担mer蠢?Ris偶eText格ureSmel垂lFres工hnes宅sTast陪eY=Ta欢ste!补!6Ove狐rvi稀ewMeas李ureStep2DefiningPerformanceStandardsforCTQsorY6Over精viewHow衰Co搅uld伸We慨Me贴asu践re僻Tas吹te尺(Y)拼?Pane剖lof祖Tas广tersRat析ing哄Sy趁ste零mof聚1t份o1时0Tar棚get雄:A仁ver己ageRati任nga膀t8Des处ire么d:遵NoInd激ivi且dua兼lR钱ati纷ngs(“d衬efe城cts昨”)润Bel姥ow蓬7Y=1宋2皮34展5霞67献8较9遍10Targ嫁etDef栽ect书sWor哨stBes西tBut口...拿..I蹄st维his拘th毕eR悟igh慢tS翻yst订em?Mea道sur洞e6Ove驰rvi乎ewStep3ValidatingtheMeasurementSystemforYHow掠Coul志dWe粥App继roac刃hTh耽is?Blin肤dfol递ded糊Pane洞lRa稳tesSev庄era产lL草oaf辩Sa萌mpl魔esPut厚“Rep亩eat”投Pie诵cesfro分mS遮ame干Lo醉af垄inDiff古eren皆tSa催mple听sCons段iste朴ntR代atin罢gs*怕onPie手ces氏fr逼om纽奉Sam虫eLoa猎f=绸“R晓epe汤ata昼bil彩ity乐”Con矿sis辨ten握tR帅ati六ngs际*o漠nSamp捆les袍Acro拒sst纺hePan腾el玩=忙“邪Rep消rod唯uci词bil沟ity鹿”“Repe甲atab脸ilit牵y”&榨“Rep遇rodu落cibi阴lity锄”Su拢gges滚tVa王lid吵Meas小urem旺ent榴Appr桃oachPan冲elMemb累erLoa震f1Loaf钟2Loaf页3A589B491C492D898E482F591G892*Wit撇hinOne装Ta朋ste桨Un吐itMea艘sur割e6Over单viewStep4EstablishProductCapabilityforY(Taste)Thi务si悦sa谜3Proc检ess!7Def摊ect横s(rati违ngs距belo搞w7)24Rat孟ing瞒s(fro球mo猜ur胞pan剪el)=.292292左,00箭0Defe缠cts迈per1,oo良o,oo烛oLo境avesOR765432112345678910#ofRatingsRating64321143Defects<7Target=8Anal暖yzeHow状DoW棍eAp勿proa券chT兽his?Bak卸eS洁eve永ral升Lo汉ave揉sUnde也r“N侄orma机l”Cond甚itio矮nsHave熊Tas喷ter帐Pane章lAgai图nDo杜the尺Rat菠ingAver抽age朋Rati挑ngi湖s7.否4But这Vari只atio浩nistoo瞒Grea桑tfo号ra指6Proc愉ess3x10+4x9+6x8+4x7+3x6+2x5+1x4+1x31+1+2+3+4+6+4+36Ove疫rvi蒙ew

Step5DefineImprovementObjectivesforY(Taste)How污do叶we堤De导fin迟eI炭mpr干ove正men反t?Ben嫩chm得ark摆th册eCom锹pet荡iti内onFoc透us顾on勾Def庆ect环s(i社.e.茎ta仇ste驾ra特tin蚕g<倍7)Dete追rmin厉eWh缠atis听an娱“Ac缩慧cep设tab弃leSig愧ma见Lev禾el”Set睛Im茎pro束vem稠entObj续ect桑ive映sAcco它rdin校glyMayb泡ea厕5Pro砖ces鹿sW疤ill小Su尼ffi系ce!1,00村0,00皮0-100,奴000犹-僻.候..撇..唇..葡..扫..狐..甲..品..挂..出..棕..者..休..捷..10,叔000壮-患.滋..暮.某..储.挤..悲.耕..魄.共..支.臣..集.镇..疤.厘..驳.屋..嗽.考.1,00虾0-室..置..想..房诚..聪..飞..驴..赔..杯..秩..乞..圈..登..稠..渔.100郑-容.肺..探..钱..樱..丧..列..亩..咐..饲..绣..声..晒..戒..脊..10出-莲..课.歼..异.粒..遣.奥..昌.波..隶.摧..亮.睡..鹊.修..端.荒..咬.良..1布-2岸3墨4茄5蛋6抢7“BETT旋ERB肤READ冷”Bak浑ing趁Pr艰oce掀ssBes尿tComp魄etit眼orRan疗ge答forImp叫rov猴eme唯ntDef止ect块sPer誓Mill戒ionSigm裙aSc蜂ale

Freihofer

WONDER

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FLOUR

FLOUR

FLOURBrandABrandBBrandCImpr蚕oveResults:350&BrandAisBestCombinationofTemperature&Flour

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BrandAFlourtobeUsedExceptinCaseofEmergency

“BETTERBREAD”toSearchforBetterAlternativeSupplierofFlourJustinCase

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